CN1128008A

CN1128008A - Method for manufacturing vehicle structural bodies

Info

Publication number: CN1128008A
Application number: CN94192901A
Authority: CN
Inventors: 大角尚武; 井上正史
Original assignee: Hitachi Ltd
Current assignee: Hitachi Ltd
Priority date: 1993-06-29
Filing date: 1994-06-27
Publication date: 1996-07-31
Also published as: EP0705750A1; JPH10291475A; WO1995001273A1; EP0705750A4

Abstract

A method for manufacturing vehicle structural bodies in which highly reliable vehicle structural bodies can be manufactured using laminated panels. The method comprises the steps of positioning a plurality of honeycomb panels relative to each other so as to hold them together for weld joining, and confirming joint conditions between materials constituting honeycomb panels by inspecting the weld joint portions and the vicinity of welding lines using non-destructive inspection methods such as radiation, ultrasonic, impact and hammering inspection methods.

Description

Make the method for car body structure

The present invention relates to make the method for car body structure, particularly relate to a kind of method of making car body structure, the composite panel that it is more suitable for welding with being connected as the material that constitutes car body structure is made car body structure.

In the prior art, the rolling stock structure generally is made up of the hexahedron with top, side plate, base plate and end plate.Each several part interconnects by welding.Material as for using comprises that structure uses roll plate usually, rolling or pressure-formed aluminium alloy plate, and to confirm these reliability of materials through the on-the-spot check of using.

In recent years, in order to increase the running velocity of rolling stock, it need make the weight of car body structure lighter, therefore develops the car body structure of the grating texture aluminium sheet of use welding as the primary member of car body structure.An example of the assembly technique relevant with this problem is disclosed in No. the 90468th (1991), Japanese Patent Application Publication text.

Under the situation of grating texture aluminium sheet as the basic building block of car body structure of using welding, these plates are by being welded to connect.In these plates, because the heat etching in the welding process, because distortion of materials produces ill effect on the weld zone between the basic building block of shaping plate.Complete for the unification that forms welding process, consider that the fault of construction of the metal part of these ill effects and welding is very important.

In making car body structure, at first by welding the welding process that forms the little plate of size that the grating texture aluminium sheet is formed, succeeded by by the little plate of size being joined together to form the welding process of the big plate of size, at last, comprise that by connection top board, side plate, base plate and six large-sized plates of end plate are assembled into the integral body that hexahedron forms vehicle.In the method for this assembling, owing to will be suitable for the program of special combination, qualification and the welding of each manufacturing step, thereby require suitably to check on the grating texture aluminium sheet of welding the distortion situation that causes in the variation aspect the member globality and each welding process that produces by calorific effect.As in the prior art, in structure rolling or pressure-formed material manufacture, by strengthening the thickness at adjacent elements junction surface, and plate and beam spare are combined and set up the strength reliability of made structure.These customary way purposes are the structural strengths that increase member, but all cause generation obstacle aspect the weight that alleviates assembly parts and made structure.

The purpose of this invention is to provide a kind of method of making car body structure, it can make the car body structure of being made up of the composite panel with higher reliability.

In the method for making car body structure, form each composite panel by the material that is welded to connect, link together by the many composite panels of welding again, by the step by being welded to connect many composite panels with after finishing, achieve the above object by the combination of steps of checking the material of each composite panel to connect situation to the nondestructive inspection of the neighbouring surface of the weld zone of welding partial sum composite panel by the step that is welded to connect.

Check the neighbouring surface of the weld zone of weld zone and thin plate by nondestructive inspection, discriminating is between the weld zone adjacent material, between the connecting portion of material and welding and the connection situation between the material of composite panel self, when finding any structure defective that on the connecting bridge of welding, produces owing to calorific effect, will be met the reparation of requirement by processing, this car body structure of making that makes has higher reliability.

To further narrate the present invention by accompanying drawing below, accompanying drawing is as follows:

Fig. 1 is the sketch map of an embodiment of the manufacturing process in car body structure manufacture method of the present invention.

Fig. 2 is presented at and makes the radiation method of inspection that car body structure uses among Fig. 1.

Fig. 3 is presented at and makes the ultrasonic process that car body structure uses among Fig. 1.

Fig. 4 is presented at and makes two kinds of methods that car body structure uses among Fig. 1: impact method of inspection and hammer test method.

Fig. 5 is presented at the vacuum method that the assembling car body structure uses among Fig. 1.

Fig. 6 shows the device that uses for super sonic, impact check and hammer test.

Fig. 7 shows another embodiment of the method be used to check weld zone and adjacent domain thereof.

Referring now to accompanying drawing narration one embodiment of the present of invention, Fig. 1 shows the basic manufacturing step of car body structure, and the check situation of each step.Member 1 is as the grating texture aluminium sheet of the welding of the woof that constitutes car body structure 10 (being called for short " grating texture plate " hereinafter).Grating texture plate 1 is made up of a

counter plate

2,3, the core material 4, tension member (not shown) and the attaching parts 5 that are clipped between the panel.Is that method by welding fits together with the grating texture shape at the core material 4 that forms between the

panel

2,3, as the attaching parts 5 on the tension member that forms with veneer or rolled-up stock of supporting member and the edge that is arranged on plate as the intensity of the part that reinforces the connection, forms grating texture plate 1.When making car body structure preparation plate, grating texture plate 1 will be made the shape of curved surfaces, to be fit to the shape of car body structure 10.

As at the grating texture plate made from said method 1, the connection situation between

panel

2,3 and core component 4 and tension member, the connection situation between

panel

2,3 and attaching parts 5 will be through check.To check connection situation between

panel

2,3 and core component 4 and tension member by impacting check, hammer test and supersonic test.The best standard of this check is the intensity that the intensity of connecting bridge is equal to or surpasses the structure construction material, and for example, all material that uses at these members is under the situation of aluminum alloy, and the thickness of

panel

2,3 is 1mm, and the thickness of core component is 0.4mm.To test by supersonic test, radioation test or penetration test as for the connecting bridge between

panel

2,3 and fast fitting 5.Thickness at attaching parts 5 is under the situation of 2mm, its best standard be the number of observed defective below benchmark numerical value, almost be bordering on zero.

Shown in Fig. 1 (1), when the grating texture plate 1 of a pair of adjacency and be inserted in each attaching parts 5 between the plate correct position fixedly the time, be welded together, so just obtain a small size plate SB who specifies the area size.About the check of small size plate SB, the weld seam between plate is tested by radiographic testing or pressure test, and the adjacent domain of weld seam is tested by super sonic, ballistic method or hammering method.In the check of the weld seam between plate, confirm whether each plate (being

panel

2,3 and attaching parts 5) is connected securely, and between the grating texture plate of adjacency, not have defect in material.In the check of the adjacent domain of weld seam, the calorific effect that check welding process on the

panel

2,3 of grating texture plate 1 and the weld zone between the attaching parts 5, to produce.In addition, the calorific effect that also will check welding process on the weld zone between

panel

2,3 and the core component 4, to produce.In above-mentioned examination work, find under the situation of any defective, will judge that level of defects and the scope found determine scrapping of repair and/or assembly parts.

Small size plate SB be used to form vehicle vertically on the plate formed by a succession of plate, promptly be used to form as the sidepiece of vehicle or the decomposition plate partly at top.

When check small size plate SB,,, can in short-term, automatically test by using large scale, high-precision test machine so feasible material operation and handling process ratio to them is easier to because it is little to be verified the comparison of sizes of thing.

By the plate SB that arranges that many sizes are little, make the big plate RB of size, comprise side plate 11, top board 12, base plate 13 and end plate 14.Fig. 1 (2) shows the manufacturing of sidewall paneling 11, an example as the big plate of size, small size plate SB is used as the vehicle window top 11a of the longitudinal extension that is assemblied in vehicle and the plate of wainscot 11b, pier plate 11c and access door 11d are added on the little plate SB of these sizes, and all these plates and member are fixed on their tram.Now established their position.Then by being welded to connect small size plate SB and each member.By radiographic testing or pressure test the side plate of making as described above 11 is being tested between the small size plate SB self and on the weld seam between small size plate and each member.As for the check of the adjacent domain of weld seam then using ultrasound ripple, ballistic method or hammering method.In this case, be verified thing and be included in weld zone between each small size plate SB, its weld seam is long, it is big to weld required heat, so, the permissible error of the connecting bridge assembly precision between the plate of welding permissible error of assembly precision when forming small size plate weldment is bigger, so more should note examination work.

In the big plate RB of check size, it is more favourable to examination work to use the movable calibration unit that is connected on the soldering outfit to carry out automatic checking, and above-mentioned movable calibration unit can move on the longitudinally of sidewall paneling 11.

Shown in Fig. 1 (3), the plate RB that size is big comprises sidewall paneling 11, top board 12, base plate 13 and end plate 14, with its combination and fix their tram, like this, forms structure 10 by welding these plates.In the general assembly structure, finish last assembling by a pair of end plate 14, calibration unit and its auxiliary device can be moved into by the opening portion of structure end and take out of, and this just helps improving the efficient of assembly working.

The check of the weld seam between the big plate RB of size is undertaken by radiographic testing and pressure test, and the check of the adjacent domain of weld seam is undertaken by super sonic, ballistic method or hammering method.Because the welding conditions requirement to the welding conditions of the big plate of the size plate littler than size is more strict, therefore must note more examination work.

So far, the manufacturing of structure 10 is finished, and shown in Fig. 1 (4), will carry out Leakage Test to structure 10.This check to the sealing property of structure is undertaken by vacuum method.

Now, will be described in the various methods of inspection of carrying out in the step of fitting work appointment hereinafter: radiographic testing, supersonic test, impact check, hammer test and vacuum method.By referring to Fig. 2, will at length narrate radiographic testing.In Fig. 2, by the grating texture plate 1 of automatic welding device 23 welding formation small size plate.Radiographic source 24 is installed in the subassembly self-operating welding gear 22 of automatic welding device 23.Radiation detector 26 is installed in and automatically in the row welding gear 22 synchronization-moving self-operating equipment 25 down.The weld seam inner case is because of can with the naked eye finding out on the image display apparatus 27.In order to detect by an unaided eye by image display apparatus 27, the ray by radiographic source 24 radiation penetrates weld seam 20, and make by the radiation detectors 26 in the self-operating equipment 25 down detect signal digitalized.Automatically differentiate by image measurement device 29 by the image and the device that uses a computer that people's vision can be checked.If discovery defect part, these defect parts will be recorded on the visual record device 28, and will be marked on the defect part marking arrangement 30, in order to improve the efficient of repair.

At length narrate supersonic test with reference to Fig. 3 below.In Fig. 3, at the weld zone between

panel

2,3 and the attaching parts 5 or the weld zone between

panel

2,3 and reinforcement the calorific effect that caused by welding process takes place easily, thereby produce defect in material on these weld zones.When these connecting bridges of check, detector will move through the connecting bridge of welding and the weld zone and the formed route of adjacent domain of each member.By to marking the part ultrasonic waves transmitted certainly, and observe backward waves with ultrasonic test unit 36, the defective of experimental material, for example the weld part office between a pair of member with different materials comes off.

Below will be by at length narrate method of inspection and the hammer test method of impacting with reference to Fig. 4.When the defective of material when for example the weld part office on grating texture plate 1 comes off, cause the variation of frequency-response data, the sound of material or the feature of vibration can reflect the defective of material indirectly.In Fig. 4, in order to check weld part, the adjacent domain of the weld seam of the hammer 47 bump grating texture plates 1 by having vibration sensor 48 and shock transducer 49 in inside, measure repulsive force and with compare by the intact limit partial data of bearing above-mentioned uniform impingement power, so just can on read out instrument 50, show the result of comparison.In addition, measure and analyze oscillation frequency and and the zero defect partial data compare, so just can examine the defective that then goes out material.Under the situation of comprehensive and overall test, it can amplify and emit from loud speaker by the phonoresponse device, makes it check weld zone quickly easilier, so that the checked operation personnel can just distinguish it on the physical significance.

At last, narrate the vacuum test method of testing the leak tightness of making the structure that finishes by reference Fig. 5.When moving in the tunnel, under pressure wave, enough mechanical strengths support himself the railway vehicle that runs at high speed except that needs have, and also need to have enough leak tightnesss.Make have designated length and and the ambient atmosphere vacuum tank 53 of isolating cover on the weld seam 20 of the structure 20 that the grating texture plate by welding constitutes, extract the inner air of vacuum tanks out by vacuum pump 53, and lowland reduction internal pressure as far as possible.A kind of miscellaneous gas of being made up of air and helium is full of grating texture plate 1 by the little permeability hole on core component 4,, just can checks out the existence of defect in material by the helium density that helium detector 55 is surveyed in vacuum tank 53.In order to determine the position of defect part, on the surface of weld seam, be coated with shaped material, the position of defect part just can be known in the position that occurs bubble from the teeth outwards.This Leakage Test mainly is the check at the connecting bridge between the big plate of size, but also can check the connecting bridge of the little plate self of the big plate of size or size by this Leakage Test.After the structure manufacturing finishes, carry out this Leakage Test, can reduce the number of the weld zone that needs check, improve checkability.

Fig. 6 shows the device that is used for supersonic test, impacts check and hammer test.This device by be used for supersonic test, impact check or hammer test detector 61, be used to support detector 61 supporting member 62, be used for its axially on moveable support 62 bloating plant 63, be used for axially perpendicular direction on mobile bloating plant 63 mobile device 64, be used to support and guide the guide rail 65 of mobile device 64, and be used for the framework 67 that support rails 65 has many air extractors 66 and form.Air extractor 66 is connected on the vacuum pump, so can be adsorbed on framework on the object that is verified.For example, detector 61 moves along being verified object surfaces by using air extractor to be adsorbed on the structure and by bloating plant 63 and mobile device 64, therefore can on predetermined slit, reach the purpose of check, can check any preposition according to this device, and to open shape irrelevant with being verified object surfaces.

Fig. 7 shows another embodiment of the method be used to check weld zone and adjacent domain thereof.The device that is used to implement this method is the supersonic test device.This device is by the oblique angle ultrasonic detector 71 that is used to check weld zone 20, is used to check the vertical ultrasonic detector 72 at the weld zone at the contiguous place of weld zone 20, and the framework 73 that is used to install above-mentioned detector is formed.Vertical ultrasonic detector 72 is installed in the both sides of oblique angle ultrasonic detector 71.The weld zones that vertical ultrasonic detector 72 is used to check panel 2, attaching parts 5 and is close to the place at weld zone 20.According to this device, can easily check weld zone and its adjacent domain simultaneously.

Also have a kind of method of inspection that is different from the above-mentioned method of inspection, it is used in particular for the check of mono-grating texture plate 1, and it is the inner chamber of compressed-air supply grating texture plate by the list structure that protrudes on hole on the core component of plate and the surface at plate.Owing to expand, the list structure that protrudes on the surface of the distortion of plate changes and informs coming off of sheet material.As for the method for inspection of weld zone, following method is feasible.When the grating texture plate of a pair of vicinity of bonded assembly, form continuous cavity space owing between them, inserting attaching parts.Owing to stopped up the two ends in continuous cavity space, the just air that can supply with and contain therein by inspection or the leakage part of special gas can be checked the defect in material of weld zone.On the defect in material part, can carry out the check of gas leakage by some mechanical means or use shaped material.

According to above narration of the present invention, can check out the defective of material by checking weld zone and neighbouring surface thereof effectively, just can produce the very firm structure of the railway vehicle that is applicable to high-speed cruising.

Claims

1. pass through the manufacture method of the car body structure of the many composite panels formation of connection, every block of plate links together by the welding unit material, and it comprises the steps:

By being welded to connect described many composite panels;

After finishing the described step that is welded to connect, by the nondestructive inspection of the adjacent domain of the weld zone of described composite panel and described weld zone being checked the situation that is connected of the described woof of described composite panel.

2. by being welded to connect the manufacture method of the car body structure that many composite panels form, every block of plate links together by the welding unit material, and it comprises the steps:

Make the small size plate by being welded to connect described many composite panels, and check described weld zone and the described weld zone adjacent domain that goes up the size plate;

Make the large scale plate by being welded to connect described small size plate, and check described large scale plate; And

By being welded to connect described large scale plate manufacturing structure body, and check described structure.

3. the manufacture method of the car body structure of being made by composite panel, it comprises the steps:

Location and many plates that fixedly are mutually related, and be welded to connect these plates;

By using radiation, super sonic, impact and hammer test method to check the adjacent domain of the connecting bridge and the weld seam of welding, the connection situation between the material that constitutes each plate for confirmation.